Building System Pre-Assembled into into Panelized Modular Components that Provides for the Reuse of the Building System Component Parts to Construct Permanent Structures of Any Size, Layout, or Style

ABSTRACT

A building system utilizing commercially available component parts, preassembled into panelized and modular components that are easily and quickly assembled and disassembled, and a lightweight compact building system for efficient transport and assembly, not requiring a central manufacturing plant or specialized construction details. A building system to provide for numerous building floor plan layouts and configurations, and a building system that provides for the reuse of the building system component parts to construct permanent structures of virtually any size, floor plan layout, or architectural style.

REFERENCES CITED U.S. Patent Documents

7,021,009 B2 April 2006 Johnson 52/79.5 4,910,932 March 1990 Honigman 52/280 3,971,172 July 1976 Gentil 52/28 4,744,182 May 1998 Shacket et al. 52.79.8 4,584,801 April 1986 Weinberger 52/64 5,070,661 December 1991 Lo Guidici 51/79.1 5,127,201 July 1992 Skvaril 52/34 4,065,905 January 1978 van der Lely 52/741 7,418,805 B2 September 2008 Tan 52/582.2 5,257,440 November 1993 Bardou et al. 24/287 4,235,054 November 1980 Cable et al. 52/210 4,073,104 February 1978 Bolanz 52/125 5,339,798 Aug. 23, 1994 Christian 126/629 6,843,718 B2 Jan. 18, 2005 Schmitz 454/186 7,231,744 B2 Jun. 19, 2007 Cooper et al. 52/199 5,487,247 Jan. 30, 1996 Pigg 52/302.3 4,103,825 Aug. 1, 1978 Zornig 237/1 A

SUMMARY OF THE INVENTION

A building system for the rapid and efficient construction of temporary, interim, and emergency housing units, as well as for permanent structures. Any number of building configurations and sizes can be achieved using this building system. The components of the building system are commercially available, not requiring a central manufacturing plant or specialized construction details, and can be assembled using a few common tools. The pre-manufactured component parts are stacked flat for compact shipment and delivered to a location where they are quickly assembled. Once the housing units are no longer needed at the location of their assembly, they can be disassembled and either stored for use at a future date, or the component parts from several of the housing units can be combined into the construction of a permanent structure of virtually any size, shape, architectural style, and with any interior and exterior finish. Thus the initial investment in temporary, interim, or emergency housing is reinvested into a permanent structure. The remaining components not used in the permanent structure are reused in the creation of additional temporary, interim, or emergency, housing units.

BACKGROUND OF THE INVENTION

The need for affordable, easily constructed modular and panelized structures has been long standing, to fill the need for emergency and disaster relief housing, field offices, volunteer housing, and other temporary, interim, and permanent housing.

The typical modular unit in prior art is rectangular and limited in layout, configuration, and functionality. Most prefabricated modular housing units require a central manufacturing facility, which limits the production as well as shipping viability. Once on site, the prefabricated modular units face installation limitations because of the need for heavy equipment, such as cranes and forklifts. Also, in general little consideration has been given to using sustainable and recyclable materials, water/vapor/radiant barriers, insulation, utilities, ventilation, and they usually are not designed to meet international building code standards. Many of the temporary housing units in prior art are designed with special construction details and material fabrication requiring specialized facilities and training for assembly and fabrication, with subsequent additional costs and loss of practical applications. When assembled on site they require specially trained tradesman to assemble the units, making them impractical on a large scale or general application.

The prior art in the category of emergency relief housing is primarily in two categories, tents and trailers. As a quick response system tents offer immediate shelter to disaster victims, however they do not provide sustained comfortable conditions or the possibility of continued use over a period of time. Trailers offer a somewhat more livable option for disaster victims, however they historically have had numerous problems associated with their construction, and they are costly to purchase, store, and maintain. Furthermore, there is no possibility of disassembling the trailers and reusing their component parts to build permanent structures.

As compared to the known building systems in prior art, an object of this invention is to provide a building system utilizing commercially available parts, preassembled into panelized and modular components that are easily and quickly assembled and disassembled, and a lightweight compact building system for efficient transport and assembly, not requiring a central manufacturing plant or specialized construction details. Another object of this building system is to provide for numerous building floor plan layouts and configurations, and a building system that provides for the reuse of the building system component parts to construct permanent structures of virtually any size, floor plan layout, or architectural style.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an embodiment of a floor plan of the building structure including decking and ramping.

FIG. 2 is an exterior elevation of the rear window side of the building structure illustrated in FIG. 1.

FIG. 3 is an exterior elevation of the left entrance side of the building structure illustrated in FIG. 1.

FIG. 4 is an exterior elevation of the right entrance side of the building structure illustrated in FIG. 1.

FIG. 5 is an exterior elevation of the rear side of the building structure illustrated in FIG. 1.

FIG. 6 is a building section of the building structure illustrated in FIG. 3 taken substantially on the line 8_8 in FIG. 1.

FIG. 7 is another embodiment of a building structure floor plan including three (3) living areas, decking, and with no kitchenette or washroom.

FIG. 8 is another embodiment of a building structure floor plan including a linear duplex arrangement of two (2) building units with separate entry and decking.

FIG. 9 is another embodiment of a building structure floor plan including a staggered duplex arrangement of two (2) building units with separate entry and decking.

FIG. 10 is another embodiment of a building structure floor plan including an enlarged living room area, three (3) bedrooms, a kitchenette, and a washroom, with separate entry and decking.

FIG. 11 is another embodiment of a building structure floor plan including a staggered and linear quadplex arrangement of four (4) building units, with separate entry and decking.

FIG. 12 is another embodiment of a building structure floor plan including a linear building unit, two (2) bedrooms, a common kitchenette and washroom, with separate entries and common decking.

FIG. 13 is another embodiment of a floor plan including a permanent structure with an entry, living room, kitchenette, master bedroom, master bathroom, walk-in closet, second bedroom, second bathroom, and garage, assembled from the component parts of four (4) building structures, as illustrated in figures No#1 through No#30, including the base frames, floor panels, structural shear panels, head frames, interior walls & doors, roof panels, windows, and entry doors, infill framing/panels, water/vapor/radiant barriers, and interior plumbing/electrical fixtures and furnishings, assembled in accordance with the building system of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 is a floor plan of the building structure (10). The building system illustrated in plan view is comprised of the base frames (12), the floor panels (18), the shear panels (20), the window panels (26), the interior wall panels (30), the water/vapor/radiant barrier material (32), the door panels (36), the tensile fabric exterior sheathing (38), the decking and steps (40), and the ramp (42). The building system is further comprised of rigid insulation interior wall panels (44) with a finished interior surface. The plumbing and electrical fixtures (46) and interior furnishings (48) are installed and connected to the pre-installed plumbing and electrical conduits.

FIG. 2 is an exterior elevation of the rear window side of the building structure comprised of adjustable metal tripods (14), expanding anchors (16), window panels (26), roof panels (34), the utility frame (28) and roof panel (34), and the tensile fabric exterior sheathing (38).

FIG. 3 is an exterior elevation of the left entrance side of the building structure (10) illustrated in FIG. 3. The building system illustrated in the exterior elevation is comprised of adjustable metal stands (14), expanding foundation anchors (16), door panels (36), roof panels (34), the utility frame (28), the roof panels (34), and the tensile fabric exterior sheathing (38). The building system is further comprised of a transom window (50), awnings (52), and photovoltaic and solar panels (54).

FIG. 4 is an exterior elevation of the right entrance side of the building structure (10) illustrated in FIG. 3. The building system illustrated in the exterior elevation is comprised of adjustable metal stands (14), expanding foundation anchors (16), door panels (36), roof panels (34), the utility frame (28), and the tensile fabric exterior sheathing (38), a transom window (50), awnings (52), and photovoltaic and solar panels (54). The building system is further comprised of plenum vents (56) to the exterior at the utility frame (28).

FIG. 5 is an exterior elevation of the rear side of the building structure (10) illustrated in FIG. 3. The building system illustrated in the exterior elevation is comprised of adjustable metal stands (14), expanding foundation anchors (16), roof panels (34), the utility frame (28), tensile fabric exterior sheathing (38), and an awning (52).

FIG. 6 is a building section of the building structure (10) illustrated in FIG. 1 taken substantially on the line 8_8 in FIG. 1. The building system illustrated in the building section is comprised of expanding foundation anchors (16), the base frame (12), floor panels (18), the head frames (22), rigid insulation interior wall panels (44), over exterior sheathing and light gauge metal framing (45), a transom window (50), and plenum vents (56) to the exterior at the utility frame (28). The building system is further comprised of plenum vents to the interior (58), water tanks (60), graywater tanks (62), and an air gap (64) between the exterior tensile fabric (38) and the water/vapor/radiant barrier (32) wherein exterior air is drawn up through the air gap (64) from the bottom of the assembly to an air gap (64) between the metal roof (66) and the water/vapor/radiant barrier (32) at the roof panels (34). The air in the air gap (64) at the roof panel (32) is heated by the radiant heat from the metal roof (66) when exposed to solar radiant heat. The heated air expands and is drawn by convection into the plenum (68) of the utility frame (28). In the heating cycle the plenum vents (56) to the exterior are closed, and the plenum vents to the interior (58) are opened. The heated air then circulates into the interior. In the cooling cycle the windows (26) are opened. The heated air in the interior rises due to the stack effect and exits the interior through the interior vents (58) into the plenum (68) and out of the plenum vents (56) to the exterior. Further is an alternate storage battery and low voltage solar powered fan (70) to augment the flow of the naturally ventilated air. A photovoltaic and solar powered system (54) produces low voltage power for the building structure (10).

FIG. 7 illustrates another embodiment for a building structure (10) floor plan including three (3) living areas, decking, and with no kitchenette or washroom (72). The building structure (10) is modified by eliminating plumbing fixtures (46) and plumbing, removing the window panels (26), adding a door panel (36), and a deck with steps (40).

FIG. 8 illustrates another embodiment for a building structure (10) floor plan including a linear duplex arrangement of two (2) building structures with separate entry and decking (74). The building structures (10) are combined in a back-to-back arrangement into a larger building structure (74).

FIG. 9 illustrates another embodiment for a building structure (10) floor plan including a staggered duplex arrangement of two (2) building structures with separate entry and decking (76). The building structures (10) are combined in a staggered back-to-back arrangement into a larger building structure (76).

FIG. 10 illustrates another building structure (10) floor plan including an enlarged Living Room area, three (3) bedrooms, a kitchenette, and a washroom, with separate entry and decking (78). The building structures (10) are combined by removing the common wall between them creating a larger building structure and common living area (78).

FIG. 11 illustrates another embodiment for a building structure (10) floor plan including a staggered and linear quadplex arrangement of four (4) building structures, with separate entry and decking (80). Four (4) of the building structures (10) are combined in a back-to-back arrangement into a larger building structure (80).

FIG. 12 illustrates another embodiment for a building structure (10) floor plan including a linear building structure, two (2) bedrooms, a common kitchenette and washroom, and with separate entries and common decking (82). Two (2) building structures (10) are combined by eliminating the third living area and connecting the structures in a linear layout (82).

FIG. 13 is another floor plan illustrating another embodiment for a permanent structure (88) with an entry, living room, kitchenette, master bedroom, master bathroom, walk-in closet, second bedroom, second bathroom, and garage, assembled from the component parts of four (4) building structures, as illustrated in figures No#1 through No#12, including the base frames (12), floor panels (18), structural shear panels (20), head frames (22), interior walls & doors (30), rigid insulation panels (44), exterior sheathing/light gauge metal framing panels (45), plumbing fixtures (46), roof panels (34), windows (26), and entry doors (36), and constitutes the layout of one example of a preferred embodiment for a permanent structure (88) constructed from the component parts of four (4) disassembled building structures (10).

The above description and the accompanying drawings of the preferred embodiment of the invention are exemplary embodiments. It is noted that modifications of the embodiments are possible within the scope of this invention without deviating from the spirit thereof. 

1. A building system for the rapid and efficient construction of temporary, interim, and emergency housing structures, as well as for permanent structures wherein the building system can be disassembled and the component parts from a plurality of the building structures can be combined into the construction of a permanent structure of virtually any size, shape, architectural style, wherein the structural component is a lightweight metal moment frame comprised of: a rigid prefabricated modular floor frame comprised of light gauge metal sections combined into structural beams in a plurality of rectangular modules that further define openings within the said rectangular floor frame modules. Said rectangular floor frame modules with means of attachment, disassembly, and reassembly to a plurality of adjustable metal stands and foundation anchors. Said rectangular floor frame modules have a means of attachment, disassembly, and reassembly to a plurality of rectangular floor frame modules. Further said rectangular floor frame modules with a means of attachment, disassembly, and reassembly to a plurality of prefabricated structural floor panels; said prefabricated structural floor panel system comprised of metal decking of the size and gauge to span the opening in said prefabricated rectangular floor frame modules with minimal deflection under load. Said structural floor panel system is further comprised of spray foam insulation in the channel cavities of the said metal decking. Further is sheathing on both the top and bottom of the said metal decking with a means of fastening the said sheathing to said metal decking. Further said prefabricated structural floor panels with means of attachment, disassembly, and reassembly to a plurality of said rectangular floor frame modules; a vertical load and shear transfer system comprised of prefabricated structural shear panels with a means of attachment, disassembly, and reassembly to a plurality of said prefabricated modular floor frames and prefabricated modular head frames; said rigid prefabricated modular head frame comprised of light gauge metal sections combined into structural beams in a plurality of rectangular modules that further define openings within the said rectangular head frame modules. Said rectangular head frame modules have a means of attachment, disassembly, and reassembly to a plurality of rectangular head frame modules. Further said rectangular head frame modules with a means of attachment, disassembly, and reassembly to a plurality of said prefabricated structural shear panels;
 2. A building system for the rapid and efficient construction of temporary, interim, and emergency housing structures, as well as for permanent structures wherein the building system can be disassembled and the component parts from a plurality of the building structures can be combined into the construction of a permanent structure of virtually any size, shape, architectural style comprised of: said lightweight metal moment frame of claim 1; a foundation system comprised of a plurality of said adjustable metal stands and said expanding foundation anchors with means of attaching said adjustable metal stands and said foundation anchors to said lightweight metal moment frame of claim 1; Further said adjustable metal stands with a means of disassembly and reuse in the construction of said building structures and said foundation anchors with a means of disassembly; a plurality of prefabricated interior wall panels comprised of light gauge metal framing and interior wall sheathing with means for attachment of said light gauge metal framing and said interior wall sheathing. Said interior wall panels have means of attachment, disassembly, and reassembly to a plurality of said prefabricated structural floor panel systems of claim 1, and lightweight metal moment frame of claim 1; Further said interior wall panels have penetrations for interior vents to communicate between the interior of said utility frame and said interior spaces. Said interior vents have means for controlling the operation of the said interior vents; a prefabricated utility frame comprised of light gauge metal framing with means of attachment to said lightweight metal moment frame of claim 1 and prefabricated panelized structural roof panels. Said utility frame includes exterior sheathing material and metal roofing exterior sheathing on all sides to the top of the exterior tensile fabric sheathing. Said utility frame is lined with interior rigid insulation panels. Further the said utility frame, said exterior sheathing, said metal roofing exterior sheathing, and said interior rigid insulation panels have penetrations for exterior vents to communicate with said interior of the utility frame with the exterior. Said exterior vents have means for controlling the operation of the said exterior vents. Further said prefabricated utility frame with a means of disassembly and reuse in the construction of said building structures; said plurality of prefabricated panelized structural roof panels comprised of metal decking of the size and gauge to span the opening between the structural roof panel supports with minimal deflection under load. Said structural roof panel system is further comprised of sheathing on the bottom of the said metal decking with a means of fastening the said sheathing to said metal decking. Said metal decking is framed with light gauge metal sections around its perimeter. Said prefabricated panelized structural roof panels are further wrapped with water/vapor/radiant barrier material prior to the installation and attachment of the metal roofing system. Said structural roof panels have said metal roofing system with means of attachment to said metal decking and said perimeter light gauge metal sections allowing for the channel voids in the said metal decking to remain open for the circulation of ventilation in both the bottom and top channels. Further said prefabricated structural roof panels with a means of attachment, disassembly, and reassembly to a plurality of said lightweight metal moment frames; a plurality of prefabricated panelized window panels comprised of a prefabricated window and window hardware assembly and light gauge metal framing with means of attachment, disassembly, and reassembly of said prefabricated window and window hardware assembly to said light gauge metal framing. An exterior sheathing with means of attaching said light gauge metal framing and said prefabricated window and window hardware assembly to said exterior sheathing. Further a means of attachment, disassembly, and reassembly of a plurality of said prefabricated window panels to said lightweight metal moment frames of claim 1; a plurality of prefabricated panelized door panels comprised of a prefabricated door and door hardware assembly and light gauge metal framing with means of attaching, disassembly, and reassembly of said prefabricated door and door hardware assembly to said light gauge metal framing. An exterior sheathing with means of attaching said light gauge metal framing and said prefabricated door and door hardware assembly to said exterior sheathing. Further a means of attachment, disassembly, and reassembly of a plurality of said prefabricated door panels to said lightweight metal moment frames of claim 1; a plurality of prefabricated panelized infill panels comprised of light gauge metal framing and an exterior sheathing with means of attaching said light gauge metal framing to said exterior sheathing. Further a means of attachment, disassembly, and reassembly of a plurality of said prefabricated infill panels to said lightweight metal moment frames of claim 1; said water/vapor/radiant barrier material is wrapped around all exterior surfaces of the building system. All joints and seams of the said water/vapor/radiant barrier are sealed and all joints and seams at said prefabricated panelized window panels and said prefabricated panelized door panels are sealed for a complete water/vapor/radiant barrier system. Further a means of disassembly of said water/vapor/radiant barrier; said exterior tensile fabric sheathing system is installed around the exterior of the building system, including receiving channels at the top and bottom of the building structure. Said exterior tensile fabric with means for attachment to the said receiving channels, and means for tensioning the said exterior tensile fabric. Further said exterior tensile fabric with a means of disassembly and reuse in the construction of said building structures; a system of light gauge metal trims are provided to transition between the said exterior tensile fabric at the corners and joints and at said prefabricated panelized window panels and said prefabricated panelized door panels. Further said light gauge metal trims with a means of disassembly and reuse in the construction of said building structures; said system of interior rigid insulation panels are installed on the inside face of said metal infill panels, said prefabricated panelized window panels, said prefabricated panelized door panels, said bottom of said utility frame, and bottom of said prefabricated panelized structural roof panels. Said interior rigid insulation panels have means for interior sheathing on the interior side of said interior rigid insulation panels and means of attachment to rigid insulation panels. Further said interior rigid insulation panels have means of attachment, disassembly, and reassembly to a plurality of said metal infill panels, said prefabricated panelized window panels, said prefabricated panelized door panels, said bottom of said utility frame, and said prefabricated panelized structural roof panels;
 3. Said utility frame of claim 2 includes water holding tanks and means for attaching said water holding tanks to said utility frame. Said utility frame includes plumbing and electrical systems with connections to plumbing and electrical fixtures and photovoltaic solar power and heating systems. Further said utility frame of claim 2 with a means of disassembly and reuse in the construction of said building structures;
 4. Said prefabricated interior wall panels of claim 2 with provisions for said plumbing and said electrical systems with means for connecting said plumbing and said electrical systems with said plumbing and said electrical fixtures. Further said plumbing, said electrical, said photovoltaic solar power and said heating systems with a means of connection to the said utility frame of claim 2;
 5. Said plumbing and said electrical fixtures installed with means of attachment and connection to said electrical and said plumbing systems;
 6. Said prefabricated panelized structural roof panels with means for said electrical system;
 7. Said building system of claim 1 wherein the components of the building system are commercially available;
 8. Said building system of claim 2 wherein the components of the building system are commercially available;
 9. Said building system of claim 1 wherein the fabrication and assembly does not require a central manufacturing facility;
 10. Said building system of claim 2 wherein the fabrication and assembly does not require a central manufacturing facility;
 11. Said building system of claim 1 wherein the fabrication and assembly does not require specialized details;
 12. Said building system of claim 2 wherein the fabrication and assembly does not require specialized details;
 13. Said building system of claim 1 wherein the building system can be assembled using a few common tools;
 14. Said building system of claim 2 wherein the building system can be assembled using a few common tools;
 15. Said building system of claim 1 wherein the pre-manufactured component parts are stacked flat for compact shipment;
 16. Said building system of claim 2 wherein the pre-manufactured component parts are stacked flat for compact shipment;
 17. Said building system of claim 1 wherein the building structures can be disassembled and stored for use at a future date;
 18. Said building system of claim 2 wherein the building structures can be disassembled and stored for use at a future date;
 19. Said building system of claim 1 wherein the methods and materials of fabrication and assembly are sustainable, recyclable “Green” materials;
 20. Said building system of claim 2 wherein the methods and materials of fabrication and assembly are sustainable, recyclable “Green” materials;
 21. Said rigid insulation panels of claim 2 wherein joints are sealed with sealing materials to control air infiltration;
 22. Said building system of claim 2 wherein thermal bridging from prefabricated panelized window panels, prefabricated panelized door panels, and prefabricated panelized infill panels is eliminated with the utilization of separate said interior rigid insulation wall panels;
 23. Said building system of claim 2 wherein moisture within the wall cavity is eliminated utilizing the separate interior rigid insulation wall panels and ventilation between the exterior tensile fabric sheathing and the water/vapor/radiant barrier;
 24. Said building system of claim 2 wherein the said prefabricated structural floor system eliminates the need for floor joist with the use of metal decking and limitation of spans that require additional support;
 25. Said building system of claim 2 wherein the said prefabricated structural floor system includes a radiant floor heating system;
 26. Said building system of claim 2 wherein the building structure is passively ventilated, heated, and cooled comprising: an air gap between said exterior tensile fabric sheathing and said water/vapor/radiant barrier wherein air is circulated up from the bottom of the exterior wall assembly to the top of the exterior wall assembly where the said air gap is communicating with an air gap between said metal roofing system and said prefabricated panelized structural roof panels with said water/vapor/radiant barrier. Further said air gap at the said metal roofing system and said prefabricated panelized structural roof panels with said water/vapor/radiant barrier communicates with the said utility frame interior. Said air in the said air gap at the said metal roofing system and said prefabricated panelized structural roof panel with said water/vapor/radiant barrier is heated by radiant solar heat energy absorbed by the said metal roofing system. The said air in the said air gap expands and moves into said utility frame by convection drawing more air up from the said air gap in the said exterior wall assembly;
 27. Said building system of claim 26 where in the heating cycle the said utility frame exterior vents are closed and the said interior vents are opened. The said heated air is circulated from the said air gap at the said metal roofing system and said prefabricated panelized structural roof panels with said water/vapor/radiant barrier to the said interior of the said utility frame and into the said interior spaces;
 28. Said building system of claim 26 where in the cooling cycle the said utility frame exterior vents are open and the said interior vents are opened. Said windows are opened. Heated interior air rises to the ceiling due to stack effect. The said heated air is circulated from the interior spaces into said utility frame and out through the said exterior vents to the said exterior;
 29. Said building system of claim 26 wherein passive ventilation is provided;
 30. Said building system of claim 26 where a battery and said solar power low voltage fan motor is provided to augment the said passive ventilation, said heating, and said cooling system. Further a means of controlling the operation of said fan motor is provided;
 31. Said building system of claim 26 where an electric fan motor is provided to augment the said passive ventilation, said heating, and said cooling system. Further a means of controlling the operation of said fan motor is provided;
 32. Said building system of claim 2 wherein any number of building configurations and sizes can be achieved using this building system comprising: a system with a floor plan having three (3) living areas, with decking and no kitchenette or washroom; a system of back-to-back linear configurations with separate entry and decking utilizing a plurality of building structures; a system of back-to-back staggered configurations with separate entry and decking utilizing a plurality of building structures; a system of back-to-back configurations with enlarged living area created by omission of a common wall utilizing a plurality of building structures; a system of back-to-back linear and staggered configurations with separate entries and decking utilizing a plurality of building structures; a system with a linear floor plan, with two living units, a common kitchenette and washroom, with separate entries and common decking;
 33. The building system of claim 1 wherein the initial investment in temporary, interim, or emergency housing is reinvested into a permanent structure;
 34. The building system of claim 2 wherein the initial investment in temporary, interim, or emergency housing is reinvested into a permanent structure;
 35. The building system of claim 1 wherein the remaining components not used in the construction of permanent structures are reused in the creation of additional temporary, interim, or emergency, building structures;
 36. The building system of claim 2 wherein the remaining components not used in the construction of permanent structures are reused in the creation of additional temporary, interim, or emergency, building structures; 